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Flux Cores getting me down...

03-19-2012, 05:49 PM

I Usally run a millermatic 212 set up with .035 hard wire and a 75/25 argon co2 mix at work. Works great but every once in a while i'll have to run flux core because I'm outdoors. I reversed the polarity, put in knurled drive wheels and put in a fresh liner. Now comes my problems. 1 as I'm welding the wire will just stop feeding. usually with mig i just flick the lead and the wire will pop out. With FC the wire gets all rats nested inside the machine. I loosened the clamp on the wire and make sure I have a new tip but it still happens mid weld instantly. This happens once in a while running mig but with FC it's like every half hour. Any ideas would be greatly appreciated. My other issue is on thinner steel I'm getting holes in my welds. kind of like perosity i guess. When i run mig I can use the same tip all day, FC i'm using about ten.. Is this typical of FC?

I run a lot of flux core gasless wire known as innershield. Using .045 mainly Hobart 21B. I don't have that problem. I set the drive roll tension just enough so it doesn't slip when welding but if it gets stuck it will slip slightly instead of birdnesting. Very rarely does it get stuck. I assume you are using the same gun for both wires & you blow it out when switching? I keep my nozzle on for both types of wires. My gun is 15' with a .045 liner.

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I wouldn't trade solid wire w gas for non gas flux core. I weld outside too and use cardboard shields and tarps to block the wind. I just don't like non gas flux. Thats just me prob and i am sure someone who likes it will chime in.
Now i run gas flux at work all day everyday and i use lots of tips and have birds nests about once a day but the biggest prob is the company bought aftermarket tip adaptors and they are just too long and i spend lots of time grinding dow 1/2 of a new tip. Think i will take some home and wack them off in my lathe and do a proper deburring of the end...Bob

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I run a lot of flux core gasless wire known as innershield. Using .045 mainly Hobart 21B. I don't have that problem. I set the drive roll tension just enough so it doesn't slip when welding but if it gets stuck it will slip slightly instead of birdnesting. Very rarely does it get stuck. I assume you are using the same gun for both wires & you blow it out when switching? I keep my nozzle on for both types of wires. My gun is 15' with a .045 liner.

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Sounds to me like the spool is not locked in to holder or tension is too loose. I never ran flux core in my 212 but with hard wire I have never had it birds nest in the mech. The spool has to be over rolling the feed.

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Sounds to me like the spool is not locked in to holder or tension is too loose. I never ran flux core in my 212 but with hard wire I have never had it birds nest in the mech. The spool has to be over rolling the feed.

I run gas flux in my MM185 with zero problems but mine has a single wheel drive and a smooth wheel where i think the MM212 has two drive wheels, just not sure...Bob

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I run a lot of flux core gasless wire known as innershield. Using .045 mainly Hobart 21B. I don't have that problem. I set the drive roll tension just enough so it doesn't slip when welding but if it gets stuck it will slip slightly instead of birdnesting. Very rarely does it get stuck. I assume you are using the same gun for both wires & you blow it out when switching? I keep my nozzle on for both types of wires. My gun is 15' with a .045 liner.

What size wire & settings are you running?

I'm running 035 with a 15' miller lead. Are you suggesting i use a 045 liner with the 035 wire? i have my clamp as loose as it will go thats why i just dont see how its rats nesting so quick... I put a brand new liner in it when i switched to the flux. do you think the knurled wheels are pushing the wire to aggrsively. when i run mig its like you said it will slip and not tangle. its so frustrating.

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I run gas flux in my MM185 with zero problems but mine has a single wheel drive and a smooth wheel where i think the MM212 has two drive wheels, just not sure...Bob

this could be the problem because im running a 10 pound spool. Usually with the hard wire i run 30 pound spools. Am I supposed to have an adapter of some sort? the smaller spool just slides back and forth in the machine.

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Yup i have a brand spanking new MM251 with a 15' gun and i hate it. If it was mine and not the companies i would trade the 15 footer in a minute. I weld in a small area and i can't always keep the lead straight...Bob

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this could be the problem because im running a 10 pound spool. Usually with the hard wire i run 30 pound spools. Am I supposed to have an adapter of some sort? the smaller spool just slides back and forth in the machine.

There should be a large 2" id spring about 3" long to use with the small 10# spools. I have an extra one if you don't have it...Bob

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There is a nub on the back of the spool holder, if the spool is not tight to the back it will free wheel and over run the rollers causing a birds nest. I would never run smooth rollers on flux core it will not run with consistent speed, you can not get the rollers tight enough on flux core with smooth rollers with out crushing it and making it out of shape, the reason they don't run smooth rollers on aluminum and flux core!!!

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I have ran fc on my 252 using .035 wire with the u notched rollers and it works great, but from the sounds of it u definitely need the adaptor to use the 10 lb roll, the adapter is basically just a spacer too keep the roll snug to the wall of the machine so the roll can work as intended, I would strongly recommend checking the wire inlet guide, after a while the wire wears it out and it causes the birds nest effect, more so on fc and stainless, if you are using the plastic one that came with the machine I would recommend upgrading to the brass one